Door panel with plastic insert

ABSTRACT

A molded, decorative, polystyrene insert has flexible locking tabs formed in a guide flange that locks behind the backface of a door panel when the insert is pressed home in an aperture in the panel.

0 Muted Mews Petent 1151 9,631,996 Ford et a1. 1 1 Jan. 18, 1972 4 900R PA L TH PLASTHC INSERT 3,110,068 1 1 1963 Perrochat 24/73 2,733,067 1/1956 Moore 1 ..85/P 1 lnvemorsi Ralph Fflrd, Harper Woods; Donald 2,912,712 1 1/1959 Shamban .iss/P Ternes, Grosse Pointe Woods, both of 3 23 20 2 19 J e h 4 43 X Mich 3,393,431 7/l968 Saunders .35/5 [73] Assignee: Evans Products Company, Portland, Oreg. FOREIGN PATENTS OR APPLICATIONS 1221 Sept- 1969 246,388 1963 Australia ..s5/5 [21] App1.N0 860,106 89,672 1960 Denmark ..52/455 Relat d U-S- Application D t Primary Examiner-John E. Murtagh [63] Continuation of Ser. No. 681,739, Nov. 9, I967, abzm- AmmekHamess doned. 57 ABSTRACT [52] 11.8. CI .52/316, 52/455, 52 /475 A old d, decorative, polystyrene insert has flexible locking [51] ln1.Cl ..E06b 3/78 tabs formed in a guide flange that locks behind the backface of 1 1 Field of Search 1 52/31 1 a door panel when the insert is pressed home in an aperture in 52/455, 456, 510; 46/16; 40/143 the panel. 1 References Cited 9 Claims, 4 Drawing Figures UNITED STATES PATENTS 3,127,965 4/1964 Weisenberger ..52/718 PATENIEnJmsmz 86 jig}; j; LE1, El

A INVENTORS,

I I F A'Z7F/ BY D 75;;

DOOR PANEL WITH PLASTIC INSERT This application is a continuation of application No. 681,739 filed Nov. 9, 1967, now abandoned.

BACKGROUND OF THE INVENTION It has been customary for hundreds of years to relieve the flat appearance of door panels by means of intricate carving in the door panel or moldings attached to the panel. Carved doors are now so expensive that only the most wealthy can afford them and substitutes including much of the molding are generally inferior or cheap looking in appearance.

It is, accordingly, a purpose of the present invention to provide a means for decorating a door panel so that it is luxurious and ornate in appearance, rivaling that achieved by the most skilled craftsmen of earlier days, which is inexpensive and compatible in cost with ordinary appearing door panels.

BRIEF SUMMARY OF THE INVENTION This invention accomplishes the foregoing purpose by means of one or more molded polystyrene inserts that are fitted in suitable apertures in the door panel. The polystyrene may be inexpensively molded to very intricate and ornamental shapes that match or excel those obtained by skilled craftsmen and wood workers hundreds of years ago. The plastic insert of this invention may be attached to door panels composed of metal, wood, pressed wood or such other material as may be used in the construction of the door. Preferably, the plastic insert is constructed in such a way that it has flexible portions or locking tabs that will snap behind the back surface of the door panel after the insert has been pressed in place in a suitable aperture in the panel.

DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of a set of folding door panels embodying plastic inserts in accordance with this invention.

FIG. 2 is an enlarged cross section taken along the line 22 of FIG. 1;

FIG. 3 is an enlarged cross section taken along the line 33 ofFlG. l, and

FIG. 4 is an enlarged side elevation, partly broken away, as taken from the right, for example, of FIG. 1, and is in substantially full size and therefore indicates the approximate preferred dimensions of the various structural features of the plastic insert embodying the invention. Thus, the tab 35 is about 0.38 inches wide, the undercut 55 and slot 53 are about 2 inches long, and the flange 41 about 0.36 inches wide.

DESCRIPTION OF THE INVENTION The invention is illustrated in connection with a set of four folding metal door panels comprising panel sections 3 and 5 which are hinged together and sections 7 and 9 which arev hinged together and hung, preferably, in accordance with the US. Pat. Nos. 2,898,987 and 2,943,675. The two pairs of panels are hinged to the opposite sides 11 and 13 of the doorway opening. The panel sections can be opened by a pull on the handles 15 or 17. Each of the panels 3, 5, 7 and 9, is provided with four plastic pan-shaped decorative inserts 19 in accordance with the invention, but it will be apparent that the number, shape, and particular ornamental configuration of the inserts can vary widely without departing from the spirit and scope of the invention.

Each of the door panels illustrated in FIG. 1 is composed of a flat layer of sheet metal 21 and for each of the inserts 19 a suitable aperture or opening 23 is formed in the metal panel 21. Since the inserts 19 are rectangular in shape, the openings 23 will also be rectangular and slightly smaller in size than is the overall exterior dimension of an insert 19 as it appears in FIG. 1.

Each panel 19 consists of a peripheral or border section 25 which extends all the way around the circumference of the panel, and an interior ornamental wall section 27 which is integral with the boarder section 25. The insert is preferably comprises a rectangular raised molded from polystyrene plastic and for normal applications has a typical wall thickness in the section 27 of about 0.09 inches. As can be seen in FIGS. 1 and 2 particularly, the ornamental wall section 27 is symmetrical about either vertical or horizontal axes, though this is not necessary, and has a relatively flat center portion 29 and a configured and recessed border portion 31 entirely surrounding it and connecting it to the boarder and attachment section 25. As can be seen in FIG. 2, the section 31 may have scalloped or gracefully curved portions 33 which may be developed in widely different ways in accordance with artistic tastes. The range of variation in ornamental design that may be achieved in the center section 27 is extremely wide, as can be readily recognized.

Doors, of course, are subjected to forceful movement and to some abuse, and it is therefore necessary that the inserts 19 be attached in such a manner that they do not come loose and that they do not rattle or shift position. It is a function of the border section 25 to attach each insert 19 t0 the panel in such a way as to prevent undesired relative movement. Furthermore, the attachment by means of the border section 25 is preferably of such a nature as to accommodate manufacturing tolerances that may occur in forming the holes 23 in the panels or in forming the molded inserts 19. In addition, in the case of metal door panels, it is desirable that the inserts 19 be firmly attached in such a way that they can serve an acoustic sound deadening function for the door panel member.

The various objects just indicated are achieved by the preferred means of utilizing the attachment section 25 to connect the insert 19 to the panel 21. This means utilizes a series of locking tabs 35 which are formed on each of the four edges of the insert 19. The inserts 19 are preferably formed of virgin, high heat, high-impact polystyrene and since this is relatively brittle, means are provided to render the tabs 35 flexible with respect to the sections 25 and 27 of the insert.

The border section 25 comprises a flange 37 which extends in a plane parallel to the panel 21 and has a back surface 39 that fits flush against the outside or front face of the panel 21. If desired, a gasket or gasket material (not shown) may be used between the surface 39 and the door panel. The border section 25 also includes a guide or centering flange 41 and extends at right angles to the flange 37 and which has an outside surface 43 which is slightly smaller in size than is the hole 23 as best seen in FIG. 3. The flange 43 extends all the way' around the insert 19 and projects through the opening 23 and is the insert portion carrying the locking tabs 35. There are preferably three of the locking tabs 35 on the long sides of the insert 19 and two on each of the short sides.

As best seen in FIG. 3, the attachment flange 37 terminates inwardly in a perpendicular section 45 which is parallel to the flange 41 and which forms the outer edge of the portion 31 of the ornamental section 27 of the panel. The inside face 47 of the section 45 is parallel to the inside face 48 of the flange 41. A solid flange 41 connected to a solid flange 37 is relatively rigid when the insert is formed of polystyrene in which case the tabs 35 as integral parts of flange 41 would not readily deflect so as to permit attachment of the insert to the panel.

As can be seen in FIGS. 3 and 4, each tab is solid and 35 portion 49 that is formed in molding on the face 43 of the flange 41. The portion 49 tapers in thickness and terminates at its thickest point (adjacent flange face 39) in a shoulder or surface 51, which extends substantially at right angles to the outer face of portion 49 and is therefore at an angle to the surface 39 and panel 21. In a typical installation, the metal panel 21 is about 0.024 inch in thickness and the maximum distance at the outer edge of the mouth or opening 52 between surface 51 and surface 39 is about 0.030 inches. The minimum width ofthe mouth 52 is, in this instance, preferably about 0.020 inches, as seen at the slot 53 which is at the root of the locking tab 35 and extends completely across the flange 41. The insert receiving hole 23 and the width of the flange faces 43 are preferably dimensioned so that the edge of the hole 23 comes approximately at the center of face 51, as indicated in FIG. 3. The slot 53 is preferably slightly smaller than the thickness of the metal panel 21 as already indicated. Some dimensional variation in the hole or insert can therefore be tolerated and the insert tab mouths 52 will still firmly and resiliently grip the panel around the edges of holes 23.

In addition to the slot 53, which is formed in the flange 41 as an extension of the surface 39 and on either side of locking tab 35 for a distance such as illustrated in FIG. 4, there is preferably an undercut 55 (of about one thirty-second inch depth) which is coextensive in length with the slot 53 and which is formed as a recess in the face 39 between the faces 47 and 48 of the section 45 and the flange 41, respectively.

The slot 53 and the undercut 55 isolate a section 57 of the flange 41 coextensive in length with the slot and undercut from the balance of the flange 41 and except at opposite ends of the sections 57 and it therefore is capable as a simple beam of elastic movement relative to the flange 41. Thus, the insert 19 can be placed in an opening 23 and push against panel 21 and this is accommodated by the fact that the tapered tabs 35 as mounted on their flexible beam sections 57 will detect inwardly as the tapered face 49 rides over the corners of the holes 23 until such point as the nose of the surface 49 passes by the backface of the panel 21 when the tab 35 and beam section 57 will spring back in the plane offlange 41 so that the tab surface 51 is locked behind the panel 21 to hold the insert 19 tightly and snugly in place in the hole 23 as illustrated in FIG. 3.

If for any reason it is desired to remove an insert 19, this can be accomplished by deflecting all of the tabs 35 and forcing the insert 19in a reverse direction through the hole 23.

While the tab 35 as shown, is carried on a simple beam section of the flange 41, that is a section supported at opposite ends, it is apparent that it is within the scope of the invention to resiliently connect the tabs 35 to the flange 41 in other ways, such, for example as by making the support beam section ofa cantilever type.

It will now be recognized that the invention has first of all provided an inexpensive way of obtaining a finely decorated door panel by means ofa series of dished or three dimensional inserts that are formed and shaped to ornamental surface configuration as desired. Broadly, these inserts can be attached to the panel by various means, such as by separate spring clips or adhesives. Secondly, the invention has provided the insert 19 with its own means of panel attachment in the form of the resilient beam-mounted locking tabs 35.

While polystyrene plastic is presently preferred for the in sert because ofits cost, durability, and molding characteristics other plastics such as soft or rigid vinyl, nylon, polyethylene, polypropylene, acetal, cellulose acetate butyrate, or acriconitrile-butadiene-styrene or even shaped metal or molded wood fiber compositions may be used in some in stances.

Modifications in the particular structure shown and described may be made without departing from the spirit and scope of the invention.

We claim:

1. A three dimensional dished monolithic ornamental insert having a transverse imperforate wall shaped to an ornamental configuration for insertion in an opening in a panel to form an ornamental exterior surface comprising a pan-shaped sheet of relatively brittle high-impact plastic material having an interior imperforate ornamental transverse wall section and an outer circumferential flange around said wall section and adapted to be pressed against the outer surface of the panel, said insert having a centering flange with one continuous wall extending at substantially a right angle to the outer flange and integral with it and said wall section as a part of the insert, said centering flange including means providing a plurality ofwidely spaced integral resilient locking tabs transversely movable relative to the centering flange for engaging behind the panel and acting with the circumferential flange to grip the panel to press the circumferential flange against said outer panel surface and hold the insert in place in said opening, slots in the centering flange between the tabs and the circumferential flange and extending parallel to the circumferential flange and of substantially greater length than the width of the tabs and providing simple beam sections connected to the centering flange only at their opposite ends, said tabs being formed in said beam sections, said beam sections and tabs being flexible perpendicularly to the centering flange.

2. An insert as set forth in claim 1 wherein said slots are located at the juncture of the centering flange and circumferential flange and the roots of the tabs are laterally adjacent the outer edges ofthe slots.

3. An insert as set forth in claim 2 wherein the slots are slightly narrower than the thickness of the panel to which the insert is to be attached.

4. An insert as set forth in claim 3 including recesses form ed in the backface of the circumferential flange at its juncture with the centering flange providing undercuts adjacent to and substantially coextensive with the slots.

5. A door panel comprising a panel member having an opening therein, a three dimensional dished insert shaped to an ornamental configuration in said opening and having an outer circumferential flange pressed against the outer surface of the panel and a centering flange extending at substantially a right angle to the outer flange and integral with it as a part of the insert, said insert including as a part thereof means for securing the insert in place on the panel in said opening comprising a solid locking tab formed on the centering flange to engage behind the panel, said centering flange having an elongated transverse slot with its length extending parallel to said circumferential flange and substantially longer than the width of said tab and extending completely through the centering flange between the circumferential flange and the tab to provide a resilient beam section of the full thickness of the centering flange to resiliently support the tab.

6. The invention as set forth in claim 5 wherein said circumferential flange has an undercut reducing its thickness adjacent said slot.

7. A door panel comprising a panel member having an opening therein, a three dimensional dished insert shaped to an ornamental configuration in said opening and having an outer circumferential flange pressed against the outer surface of the panel and a centering flange extending at substantially at right angle to the outer flange and integral with it as a part of the insert, said centering flange having an elongated narrow transverse slot with a length parallel to the circumferential flange extending completely through it to provide a resilient beam section of the full thickness of the centering flange separated along its length from the circumferential flange and connected to the centering flange at its opposite ends and capable of deflection in a perpendicular direction with respect to the adjacent part ofthe centering flange, and a solid locking tab on said beam section to engage behind the panel, said tab being centrally located on said beam section and having a width substantially less than the length of the beam section so that beam sections extend on opposite sides of the tab.

8. ln door panel having a panel with a large nonfunctional opening therein, a three dimensional dished pan-shaped insert having an interior imperforate wall section shaped to an ornamental configuration for covering said opening, said opening and insert being provided for decorative purposes only, said insert being disposed in said opening to form a panel surface and having an outer circumferential flange pressed against the outer surface of the panel, said insert having a centering flange in said opening extending at substantially a right angle to the outer flange and integral with it as a part of the insert, said centering flange comprising one continuous wall extending across the inside of the panel opening and all around the inner circumference of said opening, means providing a multiplicity of separate elongated narrow transverse slots with the lengths thereof extending parallel to the circumferential flange, said slots extending completely through the thickness of the centering flange wall to form in the centering flange wall a multiplicity of separate resilient beam sections that are indepen- 6 in said opening.

9. The invention set forth in claim 8 wherein said panel member is metal and said insert is fonned of polystyrene and wherein said panel has a and a plurality of said openings.

plurality of said rectangular openings inserts of rectangular shape in said 

1. A three dimensional dished monolithic ornamental insert having a transverse imperforate wall shaped to an ornamental configuration for insertion in an opening in a panel to form an ornamental exterior surface comprising a pan-shaped sheet of relatively brittle high-impact plastic material having an interior imperforate ornamental transverse wall section and an outer circumferential flange around said wall section and adapted to be pressed against the outer surface of the panel, said insert having a centering flange with one continuous wall extending at substantially a right angle to the outer flange and integral with it and said wall section as a part of the insert, said centering flange including means providing a plurality of widely spaced integral resilient locking tabs transversely movable relative to the centering flange for engaging behind the panel and acting with the circumferential flange to grip the panel to press the circumferential flange against said outer panel surface and hold the insert in place in said opening, slots in the centering flange between the tabs and the circumferential flange and extending parallel to the circumferential flange and of substantially greater length than the width of the tabs and providing simple beam sections connected to the centering flange only at their opposite ends, said tabs being formed in said beam sections, said beam sections and tabs being flexible perpendicularly to the centering flange.
 2. An insert as set forth in claim 1 wherein said slots are located at the juncture of the centering flange and circumferential flange and the roots of the tabs are laterally adjacent the outer edges of the slots.
 3. An insert as set forth in claim 2 wherein the slots are slightly narrower than the thickness of the panel to which the insert is to be attached.
 4. An insert as set forth in claim 3 including recesses formed in the backface of the circumferential flange at its juncture with the centering flange providing undercuts adjacent to and substantially coextensive with the slots.
 5. A door panel comprising a panel member having an opening therein, a three dimensional dished insert shaped to an ornamental configuration in said opening and having an outer circumferential flange pressed against the outer surface of the panel and a centering flange extending at substantially a right angle to the outer flange and integral with it as a part of the insert, said insert including as a part thereof means for securing the insert in place on the panel in said opening comprising a solid locking tab formed on the centering flange to engage behind the panel, said centering flange having an elongated transverse slot with its length extending parallel to said circumferential flange and substantially longer than the width of said tab and extending completely through the centering flange between the circumferential flange and the tab to provide a resilient beam section of the full thickness of the centering flange to resiliently support the tab.
 6. The invention as set forth in claim 5 wherein said circumferential flange has an undercut reducing its thickness adjacent said slot.
 7. A door panel comprising a panel member having an opening therein, a three dimensional dished insert shaped to an ornamental configuration in said opening and having an outer circumferential flange pressed against the outer surface of the panel and a centering flange extending at substantially at right angle to the outer flange and integral with it as a part of the insert, said centering flange having an elongated narrow transverse slot with a length parallel to thE circumferential flange extending completely through it to provide a resilient beam section of the full thickness of the centering flange separated along its length from the circumferential flange and connected to the centering flange at its opposite ends and capable of deflection in a perpendicular direction with respect to the adjacent part of the centering flange, and a solid locking tab on said beam section to engage behind the panel, said tab being centrally located on said beam section and having a width substantially less than the length of the beam section so that beam sections extend on opposite sides of the tab.
 8. In door panel having a panel with a large nonfunctional opening therein, a three dimensional dished pan-shaped insert having an interior imperforate wall section shaped to an ornamental configuration for covering said opening, said opening and insert being provided for decorative purposes only, said insert being disposed in said opening to form a panel surface and having an outer circumferential flange pressed against the outer surface of the panel, said insert having a centering flange in said opening extending at substantially a right angle to the outer flange and integral with it as a part of the insert, said centering flange comprising one continuous wall extending across the inside of the panel opening and all around the inner circumference of said opening, means providing a multiplicity of separate elongated narrow transverse slots with the lengths thereof extending parallel to the circumferential flange, said slots extending completely through the thickness of the centering flange wall to form in the centering flange wall a multiplicity of separate resilient beam sections that are independently movable relative to each other in a direction perpendicular to said centering flange and are of the full thickness of the centering flange, and locking tabs on one side of said beam sections and substantially shorter than said beam sections and forming a part of each of said resilient beam sections and having locking shoulders for engaging the back of the panel at the edge of the opening to secure the insert in place on the panel in said opening.
 9. The invention set forth in claim 8 wherein said panel member is metal and said insert is formed of polystyrene and wherein said panel has a plurality of said rectangular openings and a plurality of said inserts of rectangular shape in said openings. 